International Journal of Engineering & Technology, 7 (2.

21) (2018) 367-371

International Journal of Engineering & Technology

Website: www.sciencepubco.com/index.php/IJET

Research paper

Effects of zero defects approach-a case study at

an Indian industry
K. Karunakaran1*, R. Saravanan2, P. Venkumar3, R. Sridhar4
1Associate
Professor, School of Engineering, VISTAS, Chennai, India.
2Professor
& Dean, Ellenki College of Engineering and Technology, Hyderabad, India.
3Professor & Deputy Registrar, Kalasalingam Academy of Research and Education (KARE), Tamil Nadu, India.
4Assistant Professor, School of Engineering, VISTAS, Chennai, India.

*Corresponding author E-mail:[email protected]

Abstract

Quality is free when reaches zero defects, quality is measured various aspects. The rework is carried out when the product finish not up
to the standard, which added additional expenditure. On other side if there is no chance for rework the cost of raw material and value
added cost up to that non conformity is lost. This work shares a success story and reveals a systematic scientific approach to reach zero
defects. The case study conducted in the leading supplier who focuses on climate and energy efficient solutions. The traditional powerful
quality tools employed to focus, understanding and analyse the problem. The Decision support system preferred and adopted to solve the
problem with affordable cost. The outcomes of this work measured in terms of modern Total Productive Maintenance style that is in
terms of Productivity, Quality, Cost, Delivery, Safety, Motivation and Morale (PQCDSM). The results in all the way found more
significant.

Keywords: Powerful quality tools, decision support system, modern total productive maintenance, motivation and morale (PQCDSM).

1. Introduction 2. Materials and methods

Zero-defect manufacturing strategy bring the enormous business Problem background
prospect to firm like higher productivity, better quality, high-
return of investment and innovation etc. [1] The organizational The organization is a leading supplier which focuses on climate
and operational decision making are recently supported by and energy efficient solutions. Wide range of products includes
specially designed information system called Decision support the valves, filters and regulators. This study focuses on
systems (DSS) which provides interface to decision maker. refrigerator valves in particularly shut-off valve –STC
Boshkoska et al. [2] addressed quality ranking related issue and manufacturing (Figure 1). Specific application (Cold Room) of
suggested DSS with integration of quality standards of the concern such valves is depicted in Figure 2.
and expectation of experts. Another interesting case is deduction
of faults and activation of auto recovery without human
intervention that is real time quality control capability, discussed.
by Ozgur and Wendel [3]. The fuzzy logic used for space
application was discussed for fault deduction under uncertainty by
Ribeiro [4]. [5] proposed about fuzzy logic based intelligent DSS
which detects, analyses the root cause and rectifying the problem
and validated with real coal mill data. [6] presented a case study
to achieve zero structural defects in press shop of a sheet metal
industry. [7] reviewed about condition monitoring in machining
process with neural networks. Saravanan et al [8] discussed
importance of measurement for improvement and achieved zero
defects in drill holed products by Total Productive Maintenance
approach and suggested to review the result in terms of PQCDSM.
In this paper valve manufacturing unit considered. the powerful
tools and renowned techniques were used and results are measured
in terms of PQCDSM [9]. Figure 1: Product and its purpose

Copyright © 2018 Authors. This is an open access article distributed under the Creative Commons Attribution License, which permits
unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
368 International Journal of Engineering & Technology

Figure 5: Punch mark of week and year of manufactured

Figure 2: Sample application of the Product

Figure 6: Traditional method & defect

Figure 3: Pareto analysis

Problem identification

According to Six Sigma, the Rework is one of the eight major

losses. Hence the Problem identification was carried out with help
of rework history of STC valves and analysed by means of Pareto
analysis. The self explanatory analysis has furnished in Figure 3.
The week and year Punch reworks encountered many times (587).
The phenomenon wise week and Year punch defects were
analysed and furnished in Figure 4. Week and Year of
manufacture information is mandatory for the customer claims. It
Figure 7: Results of brainstorming
usually punches on the part as week followed by year. For
example, the punch mark is 0716 means seventh week of the year
2016 (Refer Figure 5). It provides traceability of finished goods
that is helps to track back on their production records. It is
essential easy identification for any customer complaints on the
specific valve. So its quality has very high priority. The existing
method is manual and it is sequentially depicted in Figure 6.

Problem analysis

The brainstorming study session was conducted and prepared

Ishikawa diagram (Cause and Effect Diagram). The possible cases
were encircled with green (Refer Figure 7). The root cause
analyses were carried and they are diagrammatically depicted in
Figure 8 to Figure 10 for the phenomenon uneven punching,
punching with less visibility and missing of Punching Figure 8: Root cause analysis (a)
respectively.

Figure 4: Contribution of different phenomenon for the defect

International Journal of Engineering & Technology 369

Figure 12: Punching tools

Figure 9: Root cause analysis (b)

Figure 13: Punching fixtures

Figure 10: Root cause analysis (c)

Figure 14: Punching fixture with housing

Figure 11: Tools for traditional and new method

Solution to the problem

An on-line punching system is designed and implemented. For

better understanding the details are comparatively discussed with
illustrative diagrams from Figure 11 to Figure 17. Figure 15: Punching operation methods

3. Results and discussions

Saravanan et al (2001) the validation is carried out in various ways
that is PQCDSM. The results of the proposed method measured
and presented in Figure 18. The solution effects in Productivity,
Quality, Cost, Delivery, Safety, Motivation and Morale wise
measured and compared. The details are diagrammatically
illustrated from Figure 19 to Figure 23.

Figure 16: Punching operation sequences

370 International Journal of Engineering & Technology

Figure 21: Benefits by cost saving

On - Time Delivery Trend 99.78

Figure 17: Punching visibilities
102
100

Delivery In Percentage
98
96 89.2
94
92
90
88 96.7
86
84 87.2
82
80
Before After
Reliability 87.2 96.7
Availability 89.2 99.78

Figure 22: Benefits on delivery

Figure 18: Zero Rework achieved in punch of week and year of 1.2
Un Safe Condition
manufactured and other quality defects 1
No.Of Un Safe Condition

0.8

0.6

0.4

0.2

0
0
Before After
Un Safe Condition 1 0
Figure 23: Benefits on safety
Figure 19: Productivity benefits

120 100
100 100 100
100
58 60
80

60 40
40 Before
20
20 After
0

Figure 20: Benefits on quality Figure 24: Benefits on motivation and morale

The productivity benefits measured in terms of number of pieces

completed and total cycle time and achieved 36% improvement,
the cycle time per piece is reduced from 9.17 seconds to 4.18
seconds, the motion losses and man power required are
completely eliminated (refer Figure 19). According quality
aspects, the rework completely eliminated, and rejection reduced
to zero and cost saving Rs.8700/- achieved. The most important
defect of missing of Punch was reduced to zero from 69. The
rework PPM achieved zero from 48916 (refer Figure 20). The cost
benefits measured in terms of rework elimination, rejection
International Journal of Engineering & Technology 371

elimination, achieved zero motion loss and manufacturing point of [9] Saravanan R, Ponmurugarajan ST & Sivakumar TK, “Chronic Loss
view. The cost saving per annum Rs.4,72,503/- (refer Figure 21). Elimination by using TPM strategy in Manufacturing- a Case
The delivery achieved to highest value and presented in terms of Study”, 12th ISME National Level Conference on “ Challenges In
Product And Process Design And Development In The Information
reliability and availability in Figure 22. Due to automation of
Era, (2001).
punching 100% safety ensured (Figure 23) and the operator
motivation and morale were measured in terms of operator
fatigue, work nature, morale and operator relationship and ensured
100% in all categories by implementing on line punching system.
The benefits are consolidated in the Table 1 for easy reference.

Table 1: Benefits summary comparison for before and after

S.No Description Benefits Summary

Before After
1 Assembly cycle time 109 Sec 80 Sec
2 Production Qty 264 No's 360 No's
3 Productivity Less than 36% 36% Improved
4 Punching cycle time 9.17 Sec 4.18 Sec
5 Operator motion losses 7.08 Sec 0 Sec
6 Rework Qty 587 No's 0 Sec
7 Rejection Qty 29 No's 0 Sec
8 Punch Missing 69 No's 0 Sec
9 Rework PPM 79216.83 PPM 48916.67 PPM
10 Rejection Cost Rs.8700/- Rs.0/-
11 Manpower consumption 1 Manpower 0
12 Rework Cost Rs.87428.32/- Rs.53762.5/-
13 Motion Losses Rs.19842.21/- Rs.16793.28/-
14 Manufacturing Cost Rs.49686/- RS.38870/-
15 Availability 89.20% 99.78%
16 Reliability 87.20% 96.70%
18 Unsafe working condition Yes No
19 Operator fatigue 58% 100%
20 Easy to use 20% 100%
21 Operator morale 40% 100%
22 Operator relationship 60% 100%

4. Conclusion
Zero defect approach discussed with case study. The use of
traditional powerful tools and modern measure of project
outcomes (PQCDSM) also illustrated well. Lot of pictures
included for easy understanding. The tangible results achieved and
presented. This work made attempt on one product only and
suggested to extend other products to continue the journey of
success.

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